Remotely actuated safety shutoff valve with interrupter assembly and system and method for using same

ABSTRACT

A remotely actuated pilot valve provides for a pilot gas valve that includes safe lighting and complete shutoff capabilities in the event that the flame that is heating a thermocouple is extinguished, the pilot valve having a pilot flow interrupter to provide pilot gas only when initially opened. A heater system that utilizes such a pilot gas valve is provided as is a method whereby the pilot gas valve used in such a system can be remotely and electronically actuated when required. Remote actuation is accomplished by use of a solenoid that is incorporated within the valve design and which is controlled by a remote operator.

This application claims priority to U.S. Provisional Patent ApplicationNo. 63/237,280 filed Aug. 26, 2021, the contents of which are herebyincorporated by reference.

FIELD OF THE INVENTION

This invention relates generally to pilot gas valves of the type thatare intended for use with burner systems that require a continuously orintermittently burning standing pilot. It also relates generally topilot gas valves that provide safe lighting and complete shutoff in theevent that the flame that is heating a thermocouple is extinguished.This invention also relates to a safety shutoff valve that is a pilotgas valve with a pilot flow interrupter for providing pilot gas only. Inthe preferred embodiment, this construction will work to provide pilotgas only and will not allow full flow of gas when initially activated.Further, this invention relates to such a heater system that utilizessuch a pilot gas valve as well as to a method whereby the pilot gasvalve used in such a system can be remotely and electronically actuatedwhen required.

BACKGROUND OF THE INVENTION

In the art of heating, the use of gaseous hydrocarbons is well known.This includes natural gas, propane, butane and other hydrocarbon fuels.It is also well known that gas supply valves are used with gas heaters.Such valves are typically used to control the flow of gas and providesafe operation by means of a “thermocouple.” Indeed, the concept of athermocouple literally means the “coupling” of two dissimilar metals tocreate a voltage potential between them when heat is maintained. If theheat is not maintained, the voltage potential across the thermocouple isnot maintained and the electrical circuit created thereby is opened. Thethermocouple is used to monitor a pilot, but its real function is tocontrol the gas supply valve.

By way of example, many gas-fueled heating devices make use of such apilot light to ignite a main gas burner. In a situation where the pilotlight would become extinguished, for any reason, there would also be thepotential for uncombusted gas to be released into the surrounding area,thereby creating a serious risk of uncontrolled combustion, explosionand fire. To prevent such a dangerous condition, some gas supply valvesuse the thermocouple to sense when this pilot light is burning. The tipof the thermocouple is placed in the pilot flame. The resultant voltage,though small (typically greater than 5 mV), operates the gas supplyvalve responsible for feeding the pilot. So long as the pilot flameremains lit, the thermocouple remains hot and holds the pilot gas valveopen. If the pilot light goes out, however, the temperature will fallalong with a corresponding drop in voltage across the thermocoupleleads, thereby removing power from the valve. The valve closes and shutsoff the gas, halting this unsafe condition. The valve disclosed hereinfurther uses a pilot flow interrupter to provide pilot gas only.

In the area of fuel pipelines of the type that are used to transportcrude oil, for example, across long distances, it is also well known inthe art that heating stations must be placed along the pipeline atintervals that are sufficient to maintain the proper flow viscosity ofthe oil.

Accordingly, it is an object of the present invention to provide a newand useful pilot valve, system and method that include safe lighting andcomplete shutoff capabilities in the event that the flame that isheating a thermocouple is extinguished. It is another object to providea pilot valve with a pilot flow interrupter to provide pilot gas onlyand not allow full flow of gas when initially opened. It is anotherobject of the present invention to provide such a pilot valve, systemand method that can be remotely and electronically actuated whenrequired by the operator. It is still another object of the presentinvention to provide such a pilot valve and a system using a minimalnumber of parts to fabricate the pilot valve and system. It is yetanother object of the present invention to provide such a method using aminimal number of steps to remotely actuate the pilot valve and systemwhen such is required.

SUMMARY OF THE INVENTION

The remotely actuated pilot valve of the present invention has obtainedthese objects. It provides for a pilot gas valve that includes safelighting and complete shutoff capabilities in the event that the flamethat is heating a thermocouple is extinguished, the pilot valve having apilot flow interrupter to provide pilot gas only when initially opened.Further, this invention provides for a heater system that utilizes sucha pilot gas valve as well as to a method whereby the pilot gas valveused in such a system can be remotely and electronically actuated whenrequired. Remote actuation is accomplished by use of a solenoid that isincorporated within the valve design and which is controlled by a remoteoperator.

The foregoing and other features of the present invention will beapparent from the detailed description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front, top and right side perspective view of a gas pilotvalve used in accordance with the prior art.

FIG. 2 is a front, top and right side perspective view of a gas pilotvalve constructed in accordance with the present invention.

FIG. 3 is a schematic diagram of a system configured in accordance withthe present invention.

FIG. 4 is an electrical ladder diagram illustrating the functionality ofthe gas pilot valve constructed in accordance with the presentinvention.

FIG. 5 is an enlarged and cross-sectioned front elevational view of thegas pilot valve constructed in accordance with the present invention.

FIG. 6 is a view similar to that of FIG. 5 with elements of the valveshown in another operational position.

FIG. 7 is another view similar to that of FIGS. 5 and 6 with elements ofthe valve shown in yet another operational position.

FIGS. 8 and 9 show the body of the valve with a partial cross-sectionedview thereof.

DETAILED DESCRIPTION

As a preliminary matter, this application incorporates the teachings ofU.S. Pat. No. 9,011,140 issued Apr. 21, 2021 to Carlson (the '140patent). While drawings numbered 1 through 4 of the '140 patent aregenerally relevant to the present invention, it should be noted that thedrawings numbered 5 through 13 of the '140 patent are not included giventhe new valve embodiment that is the subject of the present application.

Referring now to the drawings in detail wherein like numbers representlike elements throughout, FIG. 1 illustrates a perspective view of atypical gas pilot valve assembly, generally identified 1, as it would beconstructed in accordance with the prior art. As shown, the assembly 1includes a gas supply line 2 that includes a supply shut off valve 3. Agas valve 5 includes a gas in port 6 and a gas out port 7. The valve 5also includes a pilot burner gas line 8 and a pilot burner 18. The valve5 further includes a thermocouple lead 9 and a thermocouple 19. Finally,the valve 5 includes a manual reset button 4. The gas out port 7 of thevalve 5 is connected to a heater array 17, the heater array 17 beingplaced in close proximity to the pilot burner 18 and the thermocouple19.

In application, gas flows through the supply line 2 and into the gasvalve 5 via the in port 6. The valve 5 supplies gas to the heater array17 via the out port 7. The valve 5 is also used to divert a smallersupply of gas to the pilot burner 18. As long as the thermocouple 19senses the flame from the pilot burner 18, gas will continue to flowfrom the valve 5 and into the array 17. If the array 17 ceases to burngas and generate the necessary amount of heat to maintain the currentflow through the thermocouple 19, the current flow from the valve 5 andthrough the out port 7 will cease at which point it will be necessary toactuate a reset button 4 on the valve 5 and re-light the pilot burner 18in order to re-open the valve 5 and establish gas flow through it.

Referring now to FIG. 2 , it illustrates a perspective view of a gaspilot valve assembly, generally identified 10, as it would beconstructed in accordance with the present invention. As shown, theassembly 10 similarly comprises a gas supply line 2 that includes asupply shut off valve 3. A gas valve 20 in accordance with the presentinvention includes a gas in port 26 and a gas out port 27. The valve 20also includes a pilot burner gas line out port 28 that is attached to apilot burner gas line 8 and a pilot burner 18. The valve 20 furtherincludes a thermocouple lead 9 and a thermocouple 19. Significantlydifferent from the assembly that is illustrated in FIG. 1 is the factthat the valve 20 includes an electronic controller 24, anelectronically actuated solenoid reset 22 and a manually actuated resetbutton 21. As with the assembly 1 of the prior art, the gas out port 27of the valve 20 is connected to a heater array 17, the heater array 17being placed in close proximity to the pilot burner 18 and thethermocouple 19.

In application, gas flows through the supply line 2 and into the gasvalve 20 via the in port 26. The valve 20 supplies gas to the heaterarray 17 via the out port 27. The valve 20 is also used to divert asmaller supply of gas to the pilot burner 18. As long as thethermocouple 19 senses the flame from the pilot burner 18, gas willcontinue to flow from the valve 20 and into the array 17. If the array17 ceases to burn gas and generate the necessary amount of heat that isrequired to maintain the current flow through the thermocouple 19, thecurrent flow from the valve 20 and through the out port 27 will cease aswill the pilot burner 18. At this point, it would be possible for thevalve 20 to be reset by means of the manual reset button 21 on the valve20 and re-light the pilot burner 18 in order to re-open the valve 20 andestablish gas flow through it. Alternatively, and preferably, theelectronic controller 24 would be used to electronically actuate thesolenoid reset 22 to accomplish the same functionality as that of themanual reset button 21. It is to be understood that this constructionwill also work to provide pilot gas only and will not allow full flow ofgas when initially opened. In the assembly 10 of the present invention,it would be possible to configure the valve 20 such that it wouldinclude the electronically actuated reset means only, and such is not alimitation of the present invention. In the preferred embodiment of theassembly 10 of the present invention, it is also desirable to configurethe electronically actuated reset means such that the controller 24 isremotely actuated.

Referring now to FIG. 3 , it illustrates a schematic representation of apreferred embodiment for a remotely and electronically actuated gasvalve reset assembly, generally identified 100, that would be configuredin accordance with the present invention. Specifically, the gas valve 20is disposed between a gas supply 2 and a heater 17. These componentsfunction substantially in accordance with the detailed descriptionprovided above. As shown, however, the gas valve 20 is electronicallyconnected to a programmable logic controller 32 or “PLC” that is used inaccordance with a pre-programmed scheme. In this particularconfiguration, the PLC 32 is, in turn, electronically connected to areceiver 34 and to a transmitter 35. The transmitter 35 is adapted togenerate and propagate, by means of an antenna 37, electromagnetic waves38 of the type that can be received by a remotely located receiver 43,the receiver 43 also being outfitted with an antenna 45. The receiver 43is electronically connected to a computer which is a monitor or signalgenerator 40 in this embodiment. This side of the schematicallyillustrated assembly 100 is intended to be that portion which is capableof controlling the remote actuation of the gas valve 20.

Another side of the assembly shown in FIG. 3 is shown to include asecond PLC 33 that is electronically connected to the heater 17. It isto be understood that the first PLC 32 and the second PLC 33 could beone in the same. That is, a single PLC could be used such as where theheater-side PLC 33 is “piggy-backed” by the valve-side PLC 32. Such isnot a limitation of the present invention. The second PLC 33 is alsoelectronically connected to the receiver 34 and the transmitter 35 thatis adapted to generate and propagate, by means of an antenna 36,electromagnetic waves 38 of the type that can be received by a remotelylocated second receiver 42, the second receiver 42 also being outfittedwith an antenna 44. The second receiver 43 is electronically connectedto the monitor or signal generator 40.

In a situation where the gas valve 20 and the heater 17 are shut down, asignal is sent to the second PLC 33 which results in a signal 38 beingtransmitted from the transmitter 35 via the antenna 37. The signal 38 ispicked up by the receiver 43 via the antenna 45 and relayedelectronically to the monitor or signal generator 40. At this point, itis to be assumed in this particular embodiment that the heater 17 willneed a given amount of time in order to bring the heat up to a levelwhere the remote signal can energize the valve 20. See FIG. 4 . In otherwords, actuation of the pilot light prematurely will result in the pilotlight not being sustained, with a second failed condition being relayedto the monitor or signal generator 40. In one practical application, anoperator who is not equipped with the remote actuation components asdescribed above would be required to physically go to the place wherethe heater 17 and gas valve 20 are located, actuate the gas valve 20,wait for a sufficient period of time to reach a sustained heat level,and then manually actuate the gas valve 20, that assembly resembling thetype of configuration represented by FIG. 1 . This results insubstantial time and expense to physically transport the operator to thesite of installation of the valve 20 and heater 17 as well assubstantial expense related to the operator's “down time” as he or shewaits to manually actuate the gas valve 20. In some applications, manualactuation requires that an operator walk into a remote area throughwoods, snow, rock, etc., and sometimes for miles, to perform thisoperation.

By contrast, the embodiment illustrated by FIG. 3 allows the operator toassess the situation from the monitor or signal generator 40, or evenfrom a phone line (not shown), and to remotely initiate a reset sequencewithout the need to be physically in the location of the valve 20 andthe heater 17. In this sequence the transmitter 42 and antenna 44transmit a signal 38 that is picked up by the receiver 34 and antenna36. The receiver 34 then sends a signal to the PLCs 32, 33 to reignitethe heater 17 and allow it sufficient time to reach a sustainable heatlevel for the valve 20. Once that is done, the operator can use themonitor or signal generator 40 to send a second signal to the valve 20to allow it to reset automatically, thereby reactivating the operationof the valve 20 and operation of the heater 17 continues as intended. Inthis particular embodiment, it is also preferred to allow a manualoverride for operation of the valve 20 in the event of otherunanticipated failures, such as where a catastrophic electrical failurewould prevent proper operation of the electronics mentioned herein. Theuse of this type of system in the situation discussed above where anoperator would otherwise need to walk into a remote area through woods,snow, rock, etc., and sometimes for miles, to perform manual valveactuation is indeed beneficial. In another application, use of theremote actuation of the gas valve 20 could be beneficial in heatersystems where, for example, infrared heaters are located at substantialheights above the floor of a facility where physically reaching themposes a potential hazard for the operator who has to manually actuate asupply gas valve 20. Other applications are also possible and any one ofthose mentioned here is not a limitation of the present invention.

Referring now to FIG. 4 , it shows an electronic ladder diagram ofoperation of the valve 20 in a system where a “flameless” pre-heater(not shown) is used with the valve 20 and following a situation wherethe system detects a heating failure, all in accordance with apre-programmed scheme. Starting at the top of the ladder, it will beseen that, once the remote “ON” signal that is sent remotely by theoperator is received by the PLC, the internal relay CR1 normally-opencontact is closed. Power is thereby provided to output OUT 1. At thesame time, output OUT 2 is on to start heating the flameless pre-heaterand to actuate the internal timer TD1 to start timing. In this example,the time delay is pre-programmed at 10 to 15 minutes. During this 10-15minute period, the flameless pre-heater is heating the tip of thethermocouple. After the internal timer TD1 times out, the TD1normally-open contact closes thereby energizing output OUT 3 whichenergizes the electronically-actuated solenoid reset and the internaltimer TD2 which starts timing. In this example, the time delay ispre-programmed at 30 to 60 seconds. During this 30 to 60 second period,the solenoid plunger is down and holding the seal open. Gas is flowingto the flameless heater. After the 30 to 60 second period has passed,the TD2 normally-open contact closes thereby energizing internal timerTD3, which is set for a one second time delay. After one second, the TD3normally-closed contact opens thereby de-energizing the solenoid OUT 3allowing the solenoid plunger to go up while the seal stays down. TheTD3 normally-open contact closes thereby energizing the timer TD4, whichis set for a 5 minute time delay. During this 5-minute period, thesensing device will send a signal to the PLC that the flameless heateris in operation by means of OUT 4. After 5 minutes, the TD4normally-closed contact opens to de-energize the pre-heater and theflameless heater continues to operate properly until its operation isagain interrupted for one reason or another. It is to be understood thatthis example is provided solely for purposes of understanding theoperation of the device, system and method of the present invention andis not limiting in any way. Other pre-programmed schemes could be usedas well.

Referring now to FIGS. 5-9 , they show the detailed internal structureof a remotely actuated pilot valve, again generally identified 20, thatis constructed in accordance with the present invention. A gas “in” port26 and a gas “out” port 27 are provided, as is a pilot burner gas lineout port 28. See FIG. 9 . Secured atop the valve 20 is the remotely andelectronically-actuated solenoid 22, or electrical operator. Thesolenoid 22 includes electromagnetic windings 54 that are used to createan electromagnetic field within the solenoid 22 when the solenoid 22 isto be actuated. The solenoid 22 includes a spring-loaded plunger 25 thatbiases the plunger 25 to a first position. In this position, the plunger25 includes an uppermost end 21 that allows for a manual override of thesolenoid 22 when there is no power available. The valve 20 also includesa magnet frame 62 that maintains a magnet disk 64 in contact with themagnet frame 62 when the current through the thermocouple 19 ismaintained. When the current is not maintained, as in conditionsdescribed earlier, the magnet frame 62 is unable to maintain itsconnection with the magnet disk 64. This magnet disk 64 is attached toone end of a connector 66, the other end of the connector 66 beingattached to a power unit seal 68. The power unit seal 68 is used with alower seat 69 to stop the flow of gas through the valve 20. See alsoFIGS. 8 and 9 , the latter showing the lower seat 69 and an upper seat67 by a cut-away view of the valve 20. In the position that is shown inFIG. 6 , the solenoid plunger 25 is then movable downwardly when thesolenoid 22 is actuated to urge the power unit seal 68 downwardly andaway from the lower seat 69 as well. This allows the thermocouple 19 tore-establish electromagnetic connection within the valve 20 and gas flowthrough the valve 20.

What makes this valve 20 a true safety shutoff valve is the addition ofan interrupter subassembly 70 which comprises an interrupter seal 76, aspring 74 and an upper disk 72. In FIG. 5 , the coil 54 of the solenoid22 is not energized and everything is in the non-functioning stand-bymode. Both the gas inlet 26 and the gas outlet 27 are in a safetyshutoff position whereby the lower casting seat 69 is blocked by thepower unit seal 68.

When the coil of the solenoid 22 is energized, the plunger 25 movesdownwardly. The interrupter seal 76 establishes contact with the uppercasting seat 67 that is blocking flow from the gas inlet 26 to the gasoutlet 27 as it moves the power unit seal 68 off the lower casting seat69. Until the thermocouple connection 9 receives the >5 mV from the heatsource, the coil of the solenoid 22 will need to be energized untilthe >5 mV is received making a magnetic connection between the magnetdisk 64 and the magnet frame 62 and then the coil of the solenoid 22 canbe de-energized allowing the plunger 25 to retract re-establishing theflow path from the gas inlet 26 to the gas outlet 27. See FIG. 7 . Ifthe thermocouple 19 connection senses flame loss or drops below the 5 mVrange will cause the magnet frame 62 to lose holding power which will beovercome by the spring force causing the power unit seal 68 to close.Once that happens, the power unit seal 68 will return to the lowercasting seat 69, thereby shutting off the gas flow downstream. FIG. 7shows the safety valve 20 in its “ON” position where the thermocouple 19is operating, the lower power unit is holding the magnet frame 62 andthe magnet disk 64 together, and the coil has been de-energized and theplunger 25 has retracted.

In summary, the interrupt subassembly 70 which comprises an interrupterseal 76, a spring 74 and an upper disk 72 of the valve 20 show how thisconstruction will work to provide pilot gas only and will not allow fullflow of gas when initially opened. FIG. 5 shows the valve 20 at restwith no energy going to the coil. FIG. 6 shows that, when energy isapplied to the coil, the plunger 25 moves down pushing open the lowerseat 69 and at the same time closing off the upper seat 67 with a sealallowing only pilot gas to flow. FIGS. 8 and 9 show the pilotconnection. Once the thermocouple 19 is satisfied the energy can beremoved from the coil and the lower seat 69 will stay open and the upperseat 67 returns to its rest position and full gas flow to the burner isestablished.

Based upon the foregoing, it will be seen that there has been provided anew and useful remotely actuable gas pilot valve that provides safelighting and complete shutoff in the event that the flame or heat sourcethat is heating a thermocouple is extinguished. There has also beenprovided a new and useful heater system that utilizes such a pilot gasvalve and a method whereby the pilot gas valve used in such a system canbe electronically actuated by a remote operator when required.

What is claimed is:
 1. A gas pilot valve that is remotely actuated via awireless electromagnetic signal that is transmitted from an antenna, thevalve comprising: a gas in port; a gas out port; a pilot burner gas outport; an electronically actuable solenoid, the solenoid comprisingelectromagnetic windings that are functionally adapted to create anelectromagnetic field within the solenoid when the solenoid iselectrically actuated via the wireless electromagnetic signal, and thesolenoid further comprising a spring-loaded push pin and a spring thatis used with the push pin, the push pin spring being disposed fullywithin the solenoid and further disposed to urge the push pin upwardly,the solenoid further comprising a spring-loaded push pin having anuppermost end that extends above the solenoid for manually actuatedresetting of the seal via the uppermost end of the push pin; a seal, theseal being normally held in a first position where gas flows from thegas in port to the gas out port and movable to a lower casting seat in asecond position to stop the flow of gas through the valve; aninterrupter subassembly comprising an upper casting seat, an interrupterseal, a spring, and an upper disk; and means for remotely actuating thesolenoid via either the wireless electromagnetic signal when the signalis received by an antenna or manually such that the push pin is urgeddownwardly by the actuated solenoid to reset the seal to the firstposition after the seal is in a second position where gas is preventedfrom flowing from the gas in port to the gas out port.
 2. The pilotvalve of claim 1 wherein the solenoid further comprises: a plate; anelectromagnet, the electromagnet maintaining the plate in contact withthe electromagnet when current flow through the electromagnet ismaintained; a spring-bias means for urging the plate away from theelectromagnet; and a connector, the connector comprising a first endconnected to the plate and a second end connected to the seal.
 3. Thepilot valve of claim 1 wherein the means for remotely actuating thesolenoid further comprises a programmable logic controller, thecontroller being electronically connected to the gas valve solenoid. 4.The pilot valve of claim 3 wherein the means for remotely actuating thesolenoid via a wireless electromagnetic signal further comprises: anelectromagnetic signal receiver that is electronically connected to anantenna; and an electromagnetic signal transmitter that iselectronically connected to an antenna; wherein the receiver and thetransmitter are electronically connected to the PLC for controlling theremote actuation of the solenoid via the wireless electromagnetic signalthat is transmitted and received by the antennas.
 5. The pilot valve ofclaim 1 wherein the valve is configured as an interrupt-type valve.
 6. Agas heater system that uses the pilot valve of claim 1 comprising: a gassupply line; a thermocouple and a thermocouple lead; a manually actuatedreset button; and a gas heater array, the gas heater array beingconnected to the gas out port of the valve and the gas heater arraybeing placed in proximity to the pilot burner and the thermocouple. 7.The system of claim 6 wherein the means for remotely actuating thesolenoid further comprises a programmable logic controller, thecontroller being electronically connected to the gas valve solenoid. 8.The system of claim 7 wherein the means for remotely actuating thesolenoid further comprises: an electromagnetic signal receiver; and anelectromagnetic signal transmitter; wherein the receiver and thetransmitter are electronically connected to the PLC for controlling theremote actuation of the solenoid via the wireless electromagneticsignal.
 9. A method for remotely actuating the gas pilot valve in thesystem of claim 8 comprising the steps of: processing a first signal toreignite the heater array; waiting a sufficient time to allow the heaterarray to read a sustainable heat level; and processing a second signalto reset the gas pilot valve.
 10. A method for remotely actuating thepilot valve of claim 1 the method comprising the steps of: providing aprogrammable logic controller as the means for remotely actuating thesolenoid; electronically connecting the controller to the solenoid;providing an electromagnetic receiver; providing an electromagnetictransmitter; electronically connecting the receiver and the transmitterto the programmable logic controller; electronically controlling theremote actuation of the solenoid via the wireless electromagneticsignal; and actuating the controller to reset the seal in accordancewith a pre-programmed scheme.
 11. The method of claim 10 furthercomprising the steps of: providing the spring-loaded push pin with anuppermost end extending above the solenoid for manually resetting theseal; and manually resetting the seal via the uppermost end of the pushpin.
 12. A gas pilot valve that is remotely actuated via a signal from atelephone land line comprising: a gas in port; a gas out port; a pilotburner gas out port; an electronically actuable solenoid, the solenoidcomprising electromagnetic windings that are functionally adapted tocreate an electromagnetic field within the solenoid when the solenoid iselectrically actuated via the signal from the telephone land line, andthe solenoid further comprising a spring-loaded push pin and a springthat is used with the push pin, the push pin spring being disposed fullywithin the solenoid and further disposed to urge the push pin upwardly;a seal, the seal being normally held in a first position where gas flowsfrom the gas in port to the gas out port and movable to a lower castingseat in a second position to stop the flow of gas through the valve; aninterrupter subassembly comprising an upper casting seat, an interrupterseal, a spring, and an upper disk; and means for remotely actuating thesolenoid via the telephone land line signal such that the push pin isurged downwardly by the actuated solenoid to reset the seal to the firstposition after the seal is in a second position where gas is preventedfrom flowing from the gas in port to the gas out port.